US9212967B2 - Method for monitoring the quality of industrial processes and system therefrom - Google Patents

Method for monitoring the quality of industrial processes and system therefrom Download PDF

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Publication number
US9212967B2
US9212967B2 US13/709,703 US201213709703A US9212967B2 US 9212967 B2 US9212967 B2 US 9212967B2 US 201213709703 A US201213709703 A US 201213709703A US 9212967 B2 US9212967 B2 US 9212967B2
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Prior art keywords
signal
frequency components
information content
working process
single frequency
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US20130199296A1 (en
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Giuseppe D'Angelo
Giorgio Pasquettaz
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Centro Ricerche Fiat SCpA
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Centro Ricerche Fiat SCpA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/03—Observing, e.g. monitoring, the workpiece
    • B23K26/032—Observing, e.g. monitoring, the workpiece using optical means
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M7/00—Vibration-testing of structures; Shock-testing of structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/083—Devices involving movement of the workpiece in at least one axial direction
    • B23K26/0853—Devices involving movement of the workpiece in at least in two axial directions, e.g. in a plane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/24—Seam welding
    • B23K26/26—Seam welding of rectilinear seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/32—Bonding taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/32—Bonding taking account of the properties of the material involved
    • B23K26/324—Bonding taking account of the properties of the material involved involving non-metallic parts
    • B23K26/3246—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1658—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning once, e.g. contour laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1674—Laser beams characterised by the way of heating the interface making use of laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91216—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/91221—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91951—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to time, e.g. temperature-time diagrams
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37217—Inspect solder joint, machined part, workpiece, welding result
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/45—Nc applications
    • G05B2219/45138—Laser welding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present invention relates to methods for monitoring the quality of an industrial working process, which includes identifying defects of the working process, of the type comprising the steps of:
  • Methods and systems for monitoring the quality of industrial processes are known, for instance applied to the on-line monitoring of the laser welding process, in particular in the case of metal plate welding.
  • the monitoring system is able to assess the presence of porosities in the welded area or, in the case of butt-welded thin metal plates, the presence of defects due to the superposition or to the disjunction of the metal plates.
  • Such systems in use base quality monitoring on a comparison between the signals obtained during the process and one or more predetermined reference signals, indicative of a high quality weld.
  • reference signals usually in a variable number between two and ten, are predetermined starting from multiple samples of high quality welds. This manner of proceeding implies the presence of an experienced operator able to certify the quality of the weld at the moment of the creation of the reference signals, entails time wastage and at times also material wastage (which is used to obtain the samples needed to obtain the reference signals). It would therefore be necessary, given a similar procedure, onerous in itself in terms of time and cost, for the subsequent procedure of comparison with the reference signal to be able to operate rapidly, in real time and at low cost, which does not take place in currently known systems.
  • the object of the present invention is to overcome all the aforesaid drawbacks.
  • the invention relates to a method for monitoring the quality of industrial processes having the characteristics set out in the foregoing and further characterized by the fact that it further comprises the operations of:
  • said acquired signal having multiple frequency components is evaluated as indicative of a working process with defects and a defect analysis step is performed on said signal having multiple frequency components.
  • said informative content is evaluated by calculating the variance of signals having single frequency components.
  • the method is applied preferably to laser working process acquiring as signal acquired from the process radiation emitted by the process.
  • the invention also relates to the system for monitoring the quality of industrial processes which implements the method described above, as well as the corresponding computer product directly loadable into the memory of a digital computer such as a processor and comprising software code portions to perform the method according to the invention when the product is run on a computer.
  • FIG. 1 is a block diagram showing a system that implements the method according to the invention
  • FIG. 2 shows a basic flow diagram of the method according to the invention
  • FIG. 3 is a flow diagram representing an embodiment the method according to the invention.
  • FIG. 4 shows signals processed by a step of the method according to the invention
  • FIG. 5 and FIG. 6 represent diagrams indicating respectively a defective process signal and the defective process signal with defects marked by the method according to the invention.
  • the present method is aimed to apply such mathematical instruments to methods for monitoring the quality of an industrial working process, which includes identifying defects of the working process to defect analysis of signals acquired by working processes.
  • a more complete description of such mathematical concepts can be found in the publications:
  • the Hilbert-Huang transform is chosen starting from the consideration that the signal acquired from the process, x(t), is usually a multicomponent non-stationary signal, i.e, a signal whose frequency changes over time.
  • the instantaneous frequency, ⁇ is an important characteristic: it is a time-varying parameter which defines the location of the signal's spectral peak as it varies with time. The latter may be roughly regarded as a sine wave whose frequency sweeps with time. On the contrary, a stationary signal is one whose where frequencies do not change over time.
  • any non-linear distorted waveform can be regarded as harmonic distortions, which are a mathematic artificial consequence of imposing a linear structure on a non-linear system. They may have mathematical meanings but not physical. Therefore, it is chosen here to describe a non-linear system by way of the instantaneous frequency.
  • the Hilbert transform is the easiest way to compute instantaneous frequency, through which a complex conjugate y(t) of any real value function can be determined by:
  • the Hilbert transform consists of passing the signal acquired from the working process x(t) through a system which leaves the magnitude unchanged, but changes the phase of all frequency components by ⁇ /2.
  • the analytic signal z(t) is defined as:
  • the Hilbert transform works well if applied to narrow band-passed signal.
  • EMD Empirical Mode Decomposition
  • EMF intrinsic mode functions
  • IMF intrinsic mode function
  • any function can be decomposed by the following operations:
  • the residue h 1 should satisfy the definitions of an intrinsic mode function IMF, so it should be symmetric and have all maxima positive and all minima negative. However, the hump on slope may become a local maximum after the first round of sifting, and then the residue may not satisfy the definitions of an intrinsic mode function IMF.
  • Such sifting process has two purposes, to eliminate riding waves, and to make the wave profiles more symmetric.
  • the first purpose is designed for the Hilbert transform to give a meaningful instantaneous frequency
  • the second purpose is designed in case the neighbouring wave amplitude have too large disparity.
  • the sifting process should be repeated until to extract the residue satisfying the definition of an intrinsic mode function IMF.
  • c 1 h 1k the first intrinsic mode function IMF from the data.
  • the first IMF component c 1 should contain the finest scale or the shortest period component of the signal.
  • FIG. 4 is a diagram showing the EMD decomposition in IMF components, or more specifically the components c j and final residue of a signal acquired from the working process x(t) which is a temperature signal, also shown in FIG. 4 , detected during the laser welding of polymers by the system 10 described in the following with reference to FIG. 1 .
  • the components of the EMD decomposition are usually physically meaningful, for the characteristic scales are defined by the physical data.
  • Orthogonalization of the IMF functions can be also performed. This is made in order to ensure that the IMF functions got by EMD decomposition could re-compose original signal and that there are orthogonality among IMF components. Orthogonalization of the IMF functions is described in the above cited publication Tian-li Huang, Wei-xin Ren and Meng-lin Lou, “ The orthogonal Hilbert - Huang Transform and its application in earthquake motion recordings analysis ”, The 14th World Conference on Earthquake Engineering Oct. 12-17, 2008, Beijing, China.
  • the value of IO T should be zeros, a total energy of decomposed signal E tot should be invariable and the energy leakage between any two IMF components E jk should be zero.
  • the value of orthogonality index is about from 10 ⁇ 2 to 10 ⁇ 3 .
  • the method according to the invention shall now be exemplified with reference to a laser welding method.
  • Said laser welding method constitutes only a non limiting example of industrial process which can be applied to the method for monitoring the quality of industrial processes according to the invention.
  • the reference number 10 designates a system for monitoring the quality of a laser welding process.
  • the example refers to the case of two polymer work pieces 2 , 3 which are welded together by means of a laser beam 20 .
  • the number 11 designates a laser source represented by a laser diode, coupled via a optic fiber 12 to a welding optic 13 .
  • this is obtained by the head of a Laserline LDF400-200 fiber coupled diode laser, which laser beam 20 is guided via an ⁇ 400 ⁇ m optical fiber 12 to the welding optic 13 .
  • the diode laser 11 is operated at 940 ⁇ 10 nm wavelength and the focal length used is 100 mm resulting an ⁇ 0.6 mm focal spot on the work piece.
  • the welding optic 13 is schematically shown as including a mirror 13 a , which can be also a beam splitter or semi-reflecting mirror beyond which sensors can be arranged to detect quantities from the welding process, such as radiation, and a focusing lens 13 a whereat arrives the laser beam originated by the laser source represented by the laser diode 11 .
  • the welding optic 13 is represented as including also a camera 15 and a pyrometer 14 .
  • the camera 15 acquires an image of the welding spot while the pyrometer 14 measures the temperature of such welding spot through the emitted radiation.
  • the output signals of the camera 14 a and a pyrometer 14 b are sent to an acquisition board 8 which acquires and performs the necessary conversions on the signal and supply them to a personal computer 9 for analysis and processing.
  • the method according the invention preferably acquires a signal generated by the working process, i.e. a radiation emitted by the process as a result of the development of the working process, not a signal from the tool performing the process.
  • the pyrometer 14 in the exemplary embodiment of FIG. 1 is on axis in the welding optics 13 .
  • a Dr Mergenthaler GmbH infrared pyrometer with Lascon controller is used.
  • Pyrometer model is EP100P/PCI and maximum sampling rate is 10 kHz. In the experiments the used sampling rate was 5 kHz. To limit the amount of data points the data was saved at 500 Hz.
  • the pyrometer 14 is used only for observation of weld temperature to see how defects affect the temperature.
  • the work pieces 2 , 3 are clamped by a pneumatic clamping device (not shown) equipped with pressure control, to supply the needed pressure on the work pieces 2 , 3 during welding.
  • a pneumatic clamping device (not shown) equipped with pressure control, to supply the needed pressure on the work pieces 2 , 3 during welding.
  • welding laser head 11 and welding optic 13 are kept stationary and a clamping jig with work pieces 2 , 3 is moved by a XY unit with constant speed on 10 mm/s.
  • the material used in the examples here discussed was polypropylene Sabic 579S with thickness of 1 mm.
  • the welded parts In polymer welding, the welded parts have to be kept together during welding to be able to conduct heat from lower part to upper part.
  • the temperature signal acquired by the pyrometer during time is indicated in the following with x(t), and it is the signal having multiple frequency components acquired from the industrial working process, which will be discussed by way of example in the following to illustrate the method according to the invention.
  • the method according to the invention envisages the following operation:
  • FIG. 3 an embodiment of the method of FIG. 2 is detailed.
  • the acquired signal x(t) coming from acquire operation 100 is shown.
  • a step 110 it is evaluated if the signal acquired from the process x(t) oscillates within a allowed range, specifically a temperature range TR, between minimum temperature T min allowed and a maximum temperature T max . If the acquired signal x(t) is within such range TR, the analysis is carried out by passing to the decomposition step 200 , else the method comes to a stop 120 .
  • a allowed range specifically a temperature range TR, between minimum temperature T min allowed and a maximum temperature T max .
  • the filtering step 200 of the signal x(t) to decompose the signal x(t) in a plurality of monocomponent signals, indicated as Intrinsic Mode Functions IMF 1 . . . IMF n ⁇ 1 uses an Empirical Mode Decomposition procedure to decompose the signal x(t) and get the Intrinsic Mode Functions IMF 1 . . . IMF n ⁇ 1 .
  • a step 250 of orthogonalization of the Intrinsic Mode Functions IMF 1 . . . IMF n ⁇ 1 is performed, obtaining orthogonalized Intrinsic Mode Functions OIMF 1 . . . OIMF n ⁇ 1 .
  • a step 255 partial indexes of orthogonality between two components j, and k, in the set of orthogonalized Intrinsic Mode Functions IOMF 1 . . . OIMF n ⁇ 1 , IO jk , among all the components are calculated, without considering the residue.
  • indexes IO are defined in the publication by Tian-li Huang, Wei-xinRen and Meng-lin Lou, “The orthogonal Hilbert-Huang Transform and its application in earthquake motion recordings analysis”, The 14th World Conference on Earthquake Engineering Oct. 12-17, 2008, Beijing, China.
  • a step 260 an evaluation of the values of the matrix IO is performed to control that the maximum of the absolute value of the indexes (max(abs(IO)) in the matrix is lower that a given value, for instance 1 ⁇ 10 ⁇ 12 . This ensures that there is not an actually severe energy leakage when applied EMD for the decomposition of time signals. If the condition of step 260 is not satisfied, through a step 265 a refinement of the orthogonalisation, going back to steps 250 , 255 , is performed.
  • a step 300 of analysis and calculation of the informative content of each monocomponent signal IMF 1 . . . IMF n which is performed in this embodiment on the orthogonalized components OIMF 1 . . . OIMF n ⁇ 1 , is carried out
  • the percentage of energy content represents that how much energy each component or function IMF i contains
  • the variance var i indicates the amount of information of each IMF i ;
  • the iteration indicates the computational cost of each component IMF i .
  • the variance values var i have been specifically selected to be calculated in the step 300 to analyze the welding quality without using any signal as reference.
  • the IMF n component corresponds to residue r n .
  • the temperature signal x(t) referred to the welding of polymeric materials without defect presents slow oscillations within a fixed temperature range. In presence of defects, due to different causes, the signal x(t) varies more or less abruptly. Since the EMD decomposition step 200 aims in general at decomposing a signal x into a finite sum of components, or modes, h 1 , . . .
  • the last component IMF n ⁇ 1 must contain at least a major percentage K 1 of the information, by way of preferred example the 80% of information;
  • percentages K 1 , K 2 of 80 and 20% are preferred values for laser welding, of course other values can be chosen for different processes, provided that the major percentage K 1 is substantially greater than the second percentage K 2 .
  • the step 400 comprises preferably evaluating if the above three conditions are satisfied. In the affirmative, it is considered that the signal does not present relevant defects (block 600 ) and the method is stopped (block 120 ).
  • the defect analysis procedure 500 can be started to detect the defects of the signal x(t).
  • the Hilbert-Huang transform of the signal x(t) is evaluated.
  • the output is a Hilbert Spectrum HS to be shown in a 2D or 3D image in step 520 .
  • the step 530 includes also calculating the standard deviation of the second order moment std_B 2 .
  • the steps 540 are identified, for an index k which varies from 1 to the length of the vector B 2 , e.g. the number of samples of vector B 2 , the samples of the second order moment B 2 (k) which exceed the standard deviation std_B 2 are classified as defects.
  • step 550 a new signal sig(k), representing the defect positions, is built with samples x(k) verifying the condition of step 540 . If no sample x(k) verifies the condition, by a step 560 signal sig(k) is placed equal to null and control is passed to step 570 to compose the final signal sig(k) and then a detected signal with marked defects D is produced.
  • FIG. 5 the signal x(t) for a welding with air gaps between the parts to be welded along with the maximum temperature Tmax and the minimum temperature Tmin.
  • FIG. 6 it is shown the corresponding quality evaluation, where the detected signal with marked defects D is shown, by superimposing the signal representing the defect positions sig(k) (the single defects are indicated by crosses).
  • step 510 - 570 described to perform the defect analysis procedure 500 , such as the method described in EP-A-1767308 or in EP-A-1275464.
  • the method described above allows to evaluate a signal acquired by a working process, having having multiple frequency components, which by, decomposition in single components and analysis, allows to detect if the defects are present.
  • the method therefore allows to determine in a quick way and without use of comparison to a reference signals, which signals generated by process are indicative of defects and can be analyzed in detail to determine the position and/or the type of defects. Clearly, this allows to spare time and computational power, avoiding to evaluate in depth all the acquired signals and concentrating only on the defective signals.
  • the step of comparison of the informative component of a given component, IMF n ⁇ 1 , with respect to a sum of the other components, IMF 1 . . . IMFn ⁇ 1 uses a tunable threshold, which can be established on the basis of the knowledge of the specific process. It is possible also that the threshold is obtained by a learning process.
  • the method is directed to laser welding process, but also to other working process, in particular involving laser, such as laser cutting processes.
  • the informative content is preferably chosen to be represented by a variance, in particular for welding processes, but it can be represented also by the entropy of the signal or by the autocorrelation.
  • the sensor used to acquire the signal from the process can be any of the sensors used in the known techniques of quality monitoring of industrial working processes producing a non-stationary signal.
  • the sensor can be a photodiode acquiring the radiation reflected by the spot on which the laser operates.

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JP6220718B2 (ja) * 2014-03-31 2017-10-25 日立オートモティブシステムズ株式会社 レーザ溶接良否判定方法及びレーザ溶接良否判定装置
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JP6615094B2 (ja) * 2014-06-12 2019-12-04 株式会社エンビジョンＡｅｓｃジャパン 接合状態検査方法
EP3418831B1 (fr) * 2017-06-19 2023-08-16 C.R.F. Società Consortile per Azioni Procédé permettant d'effectuer une opération d'élimination du bruit sur un signal acquis par un capteur et système associé
CN109353011B (zh) * 2018-10-30 2021-07-20 大族激光科技产业集团股份有限公司 激光焊接塑料的监测方法
CN109885002A (zh) * 2019-03-04 2019-06-14 江苏科技大学 一种焊机联网智能监控系统及监控方法
CN110308206B (zh) * 2019-08-08 2021-10-08 陕西师范大学 基于emd广义相位排列熵对相近金属材料的鉴别方法
CN111168206A (zh) * 2020-01-14 2020-05-19 佛山国防科技工业技术成果产业化应用推广中心 一种熔化极气体保护焊诊断方法及电弧信息采集装置
CN113624834B (zh) * 2021-08-11 2023-06-30 合肥工业大学 一种基于边际谱质心检测的缺陷深度识别方法、系统
CN115922066B (zh) * 2022-12-27 2024-02-13 中国重汽集团济南动力有限公司 一种基于实时同轴视觉监测的焊接熔透控制方法及系统
CN116341993B (zh) * 2023-05-29 2023-07-25 无锡兴达泡塑新材料股份有限公司 一种用于聚苯乙烯生产过程中状态监测方法及系统

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